Hyster A274 Operating instructions

Hyster A274 (H50CT) Forklift Service Repair Manual

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
PART NO. 4014306 1400 SRM 1426

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

Drive Axle and Differential Assembly Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Identification Plate........................................................................................................................................ 1
Drive Axle Repair............................................................................................................................................... 2
Remove and Disassemble.............................................................................................................................. 2
Clean and Inspect.......................................................................................................................................... 5
Assemble and Install ..................................................................................................................................... 5
Differential Repair............................................................................................................................................. 8
Remove ........................................................................................................................................................... 8
Differential Assembly From Drive Axle Center Section Assembly ........................................................ 8
Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center Section........................................... 10
Disassemble ................................................................................................................................................... 15
Differential Assembly ............................................................................................................................... 15
Drop Box Housing ..................................................................................................................................... 19
Differential Assembly Cover..................................................................................................................... 20
Drive Axle Center Section......................................................................................................................... 21
Clean and Inspect.......................................................................................................................................... 22
Assemble ........................................................................................................................................................ 23
Drive Axle Center Section......................................................................................................................... 23
Differential Assembly Cover..................................................................................................................... 25
Drop Box Housing ..................................................................................................................................... 26
Differential Assembly ............................................................................................................................... 27
Install ............................................................................................................................................................. 31
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) .................................................................. 31
Drive Pinion, Pinion Gear, and Bearings Into Drive Axle Center Section............................................. 34
Differential Assembly Into Drive Axle Center Section ........................................................................... 38
Hypoid Gear Backlash, Adjust ................................................................................................................. 41
Hypoid Gear, Runout Check ..................................................................................................................... 43
Gear Set, Tooth Contact Pattern Check................................................................................................... 43
Torque Specifications......................................................................................................................................... 46
This section is for the following models:
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
©2011 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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1400 SRM 1426 General
General
This manual covers the repair procedures for the
drive axle and differential assembly. IDENTIFICATION PLATE
There is an identification plate located on the differ-
ential assembly cover. See Figure 1.
A. FRONT OFTRUCK B. REAR OF TRUCK
1. SERIAL NUMBER
2. DATE 3. IDENTIFICATION PLATE 4. DIFFERENTIAL ASSEMBLY COVER
Figure 1. Drive Axle Identification Plate
1

Drive Axle Repair 1400 SRM 1426
Drive Axle Repair
REMOVE AND DISASSEMBLE
WARNING
When putting the lift truck on blocks, make
sure the surface is solid, even, and level. Any
blocks used to support the lift truck must be
solid, one-piece units.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck.
2. Raise lift truck and put blocks under frame so
that drive wheels do not touch floor. Put blocks
under counterweight for stability.
3. Remove mast assembly as described in section
Mast Repair 4000 SRM 1431.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
4. Remove oil drain plug and drain oil from drive
axle into a suitable container. See Figure 2. Dis-
card oil drain plug O-ring.
WARNING
On lift trucks with pneumatic tires, completely
remove air from tires before removing them
from lift truck. Air pressure in tires can cause
tire and rim parts to explode, which can cause
serious injury or death. Never loosen nuts that
hold together inner and outer wheel halves
when there is air pressure in tire.
5. Remove wheels.
NOTE: BOTTOM VIEW OF DRIVE AXLE SHOWN.
1. OIL DRAIN PLUG
2. DRIVE AXLE CENTER SECTION 3. LEFT HUB
Figure 2. Oil Drain Plug
2

1400 SRM 1426 DriveAxleRepair
6. Disconnect brake line connecting master cylinder
to brake manifold located on top of drive axle as-
sembly. See Figure 4.
7. Remove parking brake cable. Refer to section
Brake System 1800 SRM 1135 for procedures.
8. Place blocks under drive axle assembly and con-
nect slings and lifting device to drive axle.
9. Place blocks under transmission to support the
transmission while removing drive axle.
10. Remove two bolts and remove universal joint
from transmission. See Figure 3.
11. Remove transmission isolator mounting bolt
from transmission mounting bracket, located on
topofdriveaxleassembly.SeeFigure7.
12. Remove four drive axle mounting capscrews from
hanger assembly. See Figure 4.
13. Remove blocks, lower drive axle assembly, and
disengagethedriveaxleassemblyfromtrans-
mission.
14. Place blocks under the drive axle center section
assembly.
15. Remove the drive axle shafts, hub/brake drum
assemblies, and back plates. Refer to the section
Brake System 1800 SRM 1135.
16. Remove hanger assembly capscrews and hanger
assembly. Repeat this step on the opposite side.
SeeFigure4.
1. BOLTS
2. UNIVERSAL JOINT 3. DRIVE AXLE CENTER SECTION 4. TRANSMISSION MOUNTING BRACKET
Figure 3. Universal Joint Removal
3

Drive Axle Repair 1400 SRM 1426
1. CAPSCREW
2. DRIVE AXLE SHAFT
3. LOCKNUT
4. BEARING LOCKWASHER
5. WASHER
6. TAPER ROLLER BEARING
7. HUB/BRAKE ASSEMBLY
8. HUB BOLT
9. ROLLER BEARING
10. INNER SEAL
11. INNER BEARING
12. OUTER SEAL
13. WEAR SLEEVE
14. BRAKE ASSEMBLY
15. LEFT BRAKE LINE
16. DRIVE AXLE MOUNTING CAPSCREW
17. DRIVE AXLE MOUNTING NUT
18. DIFFERENTIAL COVER
19. RIGHT BRAKE LINE
20. DRIVE AXLE CENTER SECTION
21. UNIVERSAL JOINT
22. DUST COVER
23. INPUT SHAFT (YOKE)
24. BRAKE MANIFOLD
25. HANGER ASSEMBLY
Figure 4. Drive Axle
4

1400 SRM 1426 DriveAxleRepair
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
1. Clean all the parts of the drive axle assembly
with solvent.
2. Inspect the bearings and seals for damage.
3. Inspect the drive axle shafts for wear and cracks
at the flange, shaft, and damaged splines. If axle
shafts show signs of wear or damage, replace the
axle shafts.
ASSEMBLE AND INSTALL
1. Apply grease to new O-rings and install O-rings
on the hanger assemblies. See Figure 4 and Fig-
ure 5.
1. O-RING
2. HANGER ASSEMBLY
3. DRIVE AXLE SPINDLE
Figure 5. Hanger Assembly
2. Placehangerassemblyinpositionondifferential
cover. Apply Loctite® 242 to capscrews and in-
stall capscrews. Tighten capscrews in sequence
shown in Figure 6 to 90 to 99 N•m (66 to 73 lbf ft).
Repeat step for opposite side.
Figure 6. Hanger Assembly Tightening
Sequence
NOTE: Apply Loctite® 515 or High Performance RTV
Silicone Gasket Maker on the drive axle shaft flange
when installing.
3. Install the back plates, hub/brake drum assem-
blies, and drive axle shafts. Refer to the section
Brake System 1800 SRM 1135.
4. Connect slings and lifting device to drive axle.
NOTE: When installing the drive axle, ensure the
drive axle is held with the upper surface of the drive
axle against the frame. This will prevent any gap be-
tween the frame and the drive axle mount, and will
ensure even weight bearing distribution.
5. Position the drive axle in the lift truck.
NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 6.
6. Install four drive axle mounting capscrews and
nuts. Tighten capscrews to 245 to 270 N•m (181
to 199 lbf ft).
7. Install universal joint to transmission using
twobolts. Tightenboltsto30to37N•m(22to
27 lbf ft). See Figure 3.
8. InstalltheisolatorsasshowninFigure7.
5

Drive Axle Repair 1400 SRM 1426
9. Apply adhesive sealant, Loctite® 271, to trans-
mission isolator mounting bolt. Install transmis-
sion isolator mounting bolt and snubbing washer
into transmission mounting bracket, located on
topofdriveaxleassembly. Tightentheboltto
225 to 250 N•m (166 to 184 lbf ft). See Figure 7.
10. Remove blocks from under transmission.
11. Install parking brake cable. Make sure brake ca-
ble is routed properly and has no interference.
Verify that parking brake operates properly. Re-
fer to section Brake System 1800 SRM 1135.
12. Connect the brake line connecting the master
cylinder to the brake manifold located on top of
the drive axle assembly. See Figure 4.
WARNING
Add air to the tires only in a safety cage. In-
spect safety cage for damage before use. When
adding air, use a clip-on chuck with enough
hose to let the operator stand clear of the cage.
NOTE: When tightening the wheel nuts, DO NOT use
any lubricant on the studs or nuts.
13. Inflate the tires using a safety cage. Install the
wheels and nuts and tighten the nuts to 155 to
175 N•m (114 to 129 lbf ft).
14. Apply multipurpose grease with 2 to 4% molyb-
denum disulfide to new drain plug O-ring and in-
stall O-ring on drain plug. Install the drain plug
and tighten to 50 to 55 N•m (37 to 41 lbf ft). See
Figure 2.
15. Remove the fill plug and fill the drive axle to the
proper level as shown in Figure 8. See section
Periodic Maintenance 8000 SRM 1424 for oil
quantity and oil type to use. Install the fill plug.
1. TRANSMISSION MOUNTING BRACKET
2. TRANSMISSION ISOLATOR MOUNTING BOLT
3. WASHER
4. SNUBBING WASHER
5. ISOLATOR
6. TRANSMISSION
7. DRIVEAXLECENTERSECTION
Figure 7. Transmission to Center Section Housing Mounting Bolt
6

1400 SRM 1426 DriveAxleRepair
16. Remove air from brake system as described in
section Brake System 1800 SRM 1135.
17. Install mast assembly as described in section
Mast Repair 4000 SRM 1431.
18. Raise lift truck and remove blocks from under
frame and counterweight. Lower lift truck.
19. Remove blocks on each side (front and back) of
steering tires.
20. Operate lift truck and check for proper operation
and leaks.
A. LEFT SIDE VIEW B. FRONT VIEW
1. OILFILLPLUG
2. OIL FILL LEVEL 3. DRIVE AXLE CENTER SECTION
Figure 8. Oil Fill Level
7

Differential Repair 1400 SRM 1426
Differential Repair
REMOVE
For the following repair procedures, the drive axle
must be removed and disassembled. Refer to section
DriveAxleRepairforremovalanddissembleproce-
dures.
Differential Assembly From Drive Axle Center Section Assembly
STEP 1.
Using a retainer ring special tool, Hyster Part No.
1663599, loosen the differential retainer rings. If
necessary, loosen retainer ring capscrews to allow
the retainer rings to turn freely. Remove differential
retainer rings and retainer ring capscrews from
center section.
1. RETAINER RING CAPSCREW
2. DIFFERENTIAL RETAINER RING
3. DIFFERENTIAL ASSEMBLY COVER
4. DRIVE AXLE CENTER SECTION
1. RETAINER RING SPECIAL TOOL
8

1400 SRM 1426 Differential Repair
STEP 2.
Remove differential assembly cover capscrews and
remove differential assembly cover.
1. DIFFERENTIAL ASSEMBLY COVER
CAPSCREWS
2. DIFFERENTIAL ASSEMBLY COVER
3. DIFFERENTIAL ASSEMBLY
4. DRIVE AXLE CENTER SECTION
STEP 3.
Remove differential assembly from drive axle center
section.
1. DIFFERENTIAL ASSEMBLY
2. HYPOID GEAR
3. DRIVE AXLE CENTER SECTION
9

Differential Repair 1400 SRM 1426
Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center Section
STEP 1.
Remove capscrews, washers, and pinion cover.
1. CAPSCREW
2. WASHER
3. PINION COVER
4. PINION NUT
5. DRIVE AXLE CENTER SECTION
CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The
staked areas can cause damage to the pinion threads, making the pinion unserviceable.
STEP 2.
Using a small, flat chisel, unstake the pinion nut.
Remove pinion nut and washer.
1. PINION NUT
2. WASHER
3. PINION SHAFT
4. DRIVE AXLE CENTER SECTION
10

1400 SRM 1426 Differential Repair
STEP 3.
Remove input shaft (yoke), oil seal, and dust cover
from drop box housing.
1. INPUT SHAFT (YOKE)
2. DUST COVER
3. OIL SEAL
STEP 4.
Remove capscrews and washers from the drop box
housing.
1. CAPSCREW
2. WASHER
3. DROP BOX HOUSING
4. DRIVE AXLE CENTER SECTION
11

Differential Repair 1400 SRM 1426
STEP 5.
Install two capscrews removed in STEP 4 in location shown. Tighten each capscrew alternately, until drop box
housing can be removed. If the capscrews do not have enough threaded length, use a pry bar to finish removing
the housing.
STEP 6.
Remove outer tapered bearing from drop box hous-
ing.
1. INSERT TWO CAPSCREWS
1. OUTER TAPERED ROLLER BEARING
2. DROP BOX HOUSING
3. PINION SHAFT
4. DRIVE AXLE CENTER SECTION
12

1400 SRM 1426 Differential Repair
NOTE: When removing pinion shaft, be sure to retain the shims.
STEP 7.
Carefully remove pinion shaft assembly from drive
axle center section. Using a press and bearing puller,
remove inner shims and inner tapered roller bearing
from pinion shaft assembly.
1. INNER TAPERED ROLLER BEARING
2. INNER SHIMS
3. PINION SHAFT
4. DRIVE AXLE CENTER SECTION
5. DRIVEN GEAR
STEP 8.
Remove driven gear and pinion crush sleeve
1. DRIVEN GEAR
2. PINION CRUSH SLEEVE
3. DRIVE AXLE CENTER SECTION
13

Differential Repair 1400 SRM 1426
STEP 9.
Using a press or suitable soft drift, remove the outer
tapered roller bearing cup from drop box housing.
1. OUTER TAPERED ROLLER BEARING CUP
2. DROP BOX HOUSING
STEP 10.
Using a suitable soft drift, remove the pinion inner
tapered roller bearing cup.
1. PINION INNER TAPERED ROLLER BEARING
CUP
2. DRIVE AXLE CENTER SECTION
14